Industrial Segment Design Aspects: LPG Tank Sizing Vaporizer Sizing Pipe Sizing Troubleshooting
contents: ➢ Industrial Segment. ➢ Design Aspects For: • Domestic Systems. • Residential Systems. • Commercial Systems. • Industrial Systems.
Industrial Usage Factories,manufacturing plant,LPg Boilers and Asphalt plants etc. Heavy duties LPG Gas consumption from 100- 2500kg/hr. Which require a massive LPG storage tanks. Tanks from 20,000 Ltr. Up to 100,000 Ltr.
• Massive Storage Capacities reach till 115,000ltr. • Extra Hazard Cosideration As per NFPA 13. •Open Spray Nozzles and Firefighting System Required. • Additional Valves assembly are required.
➢ Filling Line Arrangement. ➢ Tank Inlet/outlet. ➢ Vapor outlet. ➢ Liquid Outlet. ➢ Vaporizer Set ➢ Vapor Line
➢ Equipmets Connections with SOV. ➢ Gas leak Detection System. • Explosion Proof features.
Filling Arrangement Filling Coupling
Tank Inlet and Outlet
Blind 1 ¼” Cap !!!!!
Internal Valves To insure high shutoff respond on the tank area. With pnoumatic operation.
HRV a hydrostatic relief valve must be installed on the filling line and on the top of LPG Tank
Water bath Vaporizer Water bath vaporisers are a special type of coil-wound heat exchanger. They are used in petrochemical and cryogenic plants to vaporise liquefied gases such as oxygen, nitrogen, argon, ethylene, propylene, and natural gas. They operate in a load range from around 500
Nm³/h to 195,000 Nm³/h. Up to three steams of different liquefied gases can be treated in one unit. Each unit comprises a round water vessel with an overflow nozzle in which a coiled tube bundle is submerged. The water bath is heated by steam lances that inject steam directly into the water. The flow of steam is adjusted by water temperature controllers. During stand-by, a small steam lance keeps the water temperature at 60°C. The water is circulated using buoyancy and gravity, enabling the system to go from zero to full capacity in two minutes.
Oil Demister LPG oil Filter after the vaporizer set to insure that there is no partical on the LPG vapor line.
ESV Emergency Shutoff valve on the filling and vapor balancing line and vapor outlet To insure high shutoff respond on the system With pnoumatic operation.
Troubleshooting • High Pressure near the Equipment’s then Pressure regulator. • Try the Internal Valve before Install it. • Flange Pressure testing. • Do Not Use Union on Tank area ((Never Ever)).
• For Underground Tank HRV Pipes. • Buffer Tanks.
• Unloading Compressor for Filling.
4-Design Criteria Sizing the LPG Tank by calculate the total LPG load. 1 Kg/hr=47,500Btu/hr. 1 KW=3,412 Btu/hr. LPG ρ =0.58kg/L.
Once the Total Amount calculated Total Gas load × Working hours /day. Total amount × storage days required by AHJ Vaporizer Selection: Total amount of Load ×1.2
Pipe Sizing.
Domestic Usage System Design: • Calculate the Total Load in Kg/hr. • Calculate the Total consumption/day. • Multiply it by the total days required by AHJ. • Decide the Pipe Sizing. • Decide the Pressure regulators capacities. • Decide the SV capacity.
Gas Power 2.75KW. /// 1 KW=3,412 Btu/hr./// 1 Kg/hr=47,500Btu/hr. (2.75*3412)/47500= 0.197 Kg/hr. Total Working Hours 4-6 hours. =0.197 kg/hr. * 5 hours = 1 kg/day (( Gas Cylinder Have 12kg/hr.)
Pipe Sizing: 2.75×3,412=9,383 Btu/hr. Find the Total Length in Ft. Confirm the Pressure Inlet and outlet. NFPA58 Chapter 15 Note: Capacities are in 1000 Btu/hr.
Pressure Regulator Selection: • Pressure In/out. Flow rate in Kg/hr. Inlet pressure 0-2 Bar. Out let 30-50 mbar. @ 0.197 Kg/hr.
Test the Gas Network @ 6Bar
LPG Gas Residential Systems Design. • Calculate the Total Load • Confirm the Natural vaporaization. • Size the Tank with proper coordination with AHJ. • 1 ¼” filling line with HRV. • Size the main Network • Size the internal Kitchen.
Resedantial Apartment contain 20 Flat. Each have 0.2 Kg/hr. and another 0.4 kg/hr. ((Total Working Hours 06 hours.)) =(0.2+0.4)kg/hr ×20 flat×06 hr.**** =72kg/day LPG @ Vapor Stage. LPG(liquid) ρ =0.58kg/L. =72/0.58>>>>>=124 L As Per AHJ the filling frequincy will be weekly 124L×7days =869 Ltr. >>>> 1,000 ltr. Tank *** Always cross check the Natural Vaporaization
Filling will be wiether Direct to tank Or with 1 ¼” filling arrangement from the main authorized road. LPG Tank will be tested at 10Bar. Filling line at 20Bar!! Why? • Pressurized filling. • Do Not Close the Filler Valve. While Testing Don’t Forget the 17.5 Bar of the HRV (Fatal Mistake).
consider each Apartment as a end with ( flowrate and Pressure)
Commercial Systems Design. • Calculate the Total Load • Size the Tank with proper coordination with AHJ. Always (divade it by Two Number ALWAYS)* • filling line with HRV. • Size the main Network. • Gas Isolation Set and Meter inside each Shop. *Maintenance and Cost Cotrol (( How))!!
A commercial Mall Have 40 Shops. Each One with 4-6 Kg/hr. Total Usage/ Day 16hr. 5kg/hr×40 Shop =200× 16 hr. =3,200 Kg/Day. LPG(liquid) ρ =0.58kg/L. =3,200/0.58 =5,517 Ltr. (( AHJ will fill each 10days.)) = Tank Required Capacity 55,170 Ltr. Always Devide it Two No. 30m³ Two Numbers.
Vaporizer Sizing and Selection: Total Kg/hr. = 200 kg/hr. * (Effecincy Factor 1.2 =200×1.2 =240Kg/hr. NFPA will not force the designer to have Stadby Vaporizer but as expart its higly recommended specially for mainteneance Purpose.
Troubleshooting for the Tank and Vaporizer • Keep the Tank Pressure Test For 6 Month !!!!! • Do Not Back fill till you test (( Never)). • At the end of the LPG Tank Area Keep Isolation Set with ESV. • All your Pipe (Underground/Aboveground) keep it tested always. • Always keep the Tank alrea piping well painted. • Vaporizer Outlet Regulator. Keep it accurate as much as possible or else one of them will trip.
Inside each Shop keep the Gas Meter Assembly which is including the below items: • Isolation Ball Valve. • Solenoid Valve. • Pressure Regulator with OPSO. Selection of the Gas Meter Based on the Flowrate G 02, G06,…… G50 Do Not Forget the OPSO Before the Meter
Gas Leak Detection System will be Weither • A Main control Panel for each Shop and one panel for the LPG Tank area. • One Panel with indivedual Relay Nodes inside each Shop.
Industial LPG Systems. Boilers Burners with High Flowrate Capacity • Size the Tanks. • Select the Vaporizer. • Select the Pipe Size. • Oil Demister. • Buffer Tank near the Equipments.
Factory With Two Main Boilers each have 400 Kg/hr. Will work for 10 Hours daily. = 400Kg/hr × 2 = 800 Kg/hr. =8000kg/Day =8000 kg/0.58 =11,379 Ltr. / day AHJ will fill each 10 days 113m³ ( Two Tanks each 60m³)
Waterbath Vaporizers Each one 800Kg/hr. After the Vaporizer 1st stage regulator From 3-6 Bar to 0.5- 1.2 Bar. With 800 flowrate. Second stage regulator from 1 Bar to the Gas Burner required Pressure.
Oil Demister Sizzing Based on the Total flowrate.
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